Project Portfolio
Will Dale
Willdale1388@gmail.com (781)-915-9186
This portfolio gives a brief overview into the major engineering
projects I’ve completed within the past 2 years.
Main Projects Include:
3-Seater Electric Vehicle Design and Fabrication (Summer 2022)
Infinity Mirror Table (Summer 2022)
3D Printed and Fiberglassed Wakefoil V1 (Summer 2021)
Circus Stunt Swing (Summer 2021)
1
3-Seater Electric Vehicle Design and Fabrication
Designed a steel frame to contain a drivetrain and steering system that fits under
an old couch using Solidworks.
2
3-Seater Electric Vehicle Design and Fabrication
Researched and built the drivetrain
system including two 3000W motors,
a jack shaft, mechanical disc brake,
and a live rear axle.
3
Designed and assembled a power
steering system using a linear actuator all
controlled wirelessly through a PS4
controller and ESP32 microcontroller
coded in C/C++.
3-Seater Electric Vehicle Design and Fabrication
4
Built a battery using 320 18650 cells with a
nominal voltage of 72V that is capable of
drawing 150 amps continuously and has a
capacity of 41Ah. (Equipped with battery
management system)
Soldered all the electronic components
including a digital potentiometer, 2 step
up converters and an ESP32 to a
protoboard.
3-Seater Electric Vehicle Design and Fabrication
5
Designed a circuit to power a horn, 2 speed controllers, 2
motors, a linear actuator, LED light under glow, a USB charging
port and battery meter; using a combination of MOSFETS,
voltage converters, microcontrollers, switches, digital
potentiometers and more.
3-Seater Electric Vehicle Design and Fabrication
6
Conclusion: I ended up with a PS4 remote controlled couch capable of moving 1,000 pounds at a
speed of about 12 MPH with a battery range of 11 miles on a full charge.
What I Learned: This project allowed me to build upon many skills such as 3D modeling, coding
(C/C++), motor control, rapid prototyping, embedded systems, battery systems, welding, time
management, budget management and more.
Infinity Mirror Table
7
Created a CAD model of a broken table I
had using Solidworks and then designed
an integrated system to create the infinity
mirrored effect.
The CAD model shows the exploded view
of the main components including the
glass pane, solar mirror film, mirror and
frame.
Infinity Mirror Table
8
Built a circuit to power four led
strips and one set of florescent
lights, all wired to a 3D printed
switch box.
Used a combination of tools and
machines such as a table saw, a
router, a dremel, chisels,
sanders, a multimeter, a
soldering iron, a 3D printer, a
drill press and more.
Infinity Mirror Table
9
Conclusion: I ended up with a table that when turned ON, creates an ”infinity mirror effect
which gives the illusion that the LED’s travel infinitely far into the floor.
What I Learned: This project further developed my skills in Solidworks modeling, circuit
building and woodworking / machine shop use.
3D Printed and Fiberglassed Wakefoil V1
3D modeled a wakefoil on Solidworks using a
basic airfoil shape as a starting point. I designed
the wing to fit with my existing wakefoil board
setup.
Perfomed a Solidworks flow simulation on the
wing to generate an aerodynamics analysis
which calculated the lift and drag of the wing.
Sliced the model into 9 different parts so I could
print them on my 3D printer.
10
3D Printed and Fiberglassed
Wakefoil V1
11
3D printed the 9 wakefoil parts using ABS
as the material.
Connected the pieces together using
wooden dowels and epoxy.
Fiberglassed the wing using 4oz fiberglass
cloth and marine epoxy.
Filled all the imperfections of the wing
using Bondo and sanded it down smooth.
3D Printed and Fiberglassed Wakefoil V1
Conclusion: I ended up with a meter long wakefoil wing that was mildy successful
as I was able to achieve a 30 second ride. However, the wing was a little too flexible
and therefore caused instability.
What I Learned: This project further developed my skills in Solidworks modeling,
rapid prototyping, fiberglassing and machine shop use. I learned that fiberglass is
actually quite flexible and a fiber such as carbon would provide a more rigid wing
for version 2.
12
Circus Stunt Swing
13
Designed a stunt swing made of wood timbers and
other components such as bearings, metal
brackets and a steel rod.
The swing consists of 3 main parts, two triangular
support structures with a middle swinging
platform.
Circus Stunt Swing
14
Conclusion: I ended up assembling the 14-foot-
tall structure on my parent's dock and used it
to jump into the water.
What I Learned: This project further developed
my skills in using shop tools, rapid prototyping
and force/moment calculations.